scholarly journals Bending Fatigue Behavior of 17-4 PH Gears Produced by Additive Manufacturing

2021 ◽  
Vol 11 (7) ◽  
pp. 3019
Author(s):  
Franco Concli ◽  
Luca Bonaiti ◽  
Riccardo Gerosa ◽  
Luca Cortese ◽  
Filippo Nalli ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Specific Resistance ◽  
Fatigue Behavior ◽  
Powder Bed ◽  
Bending Fatigue ◽  
Experimental Campaign ◽  
Single Tooth ◽  
Final Failure ◽  
Effective Design ◽  
Resistance Data

The introduction of Additive Manufacturing (AM) is changing the way in which components and machines can be designed and manufactured. Within this context, designers are taking advantage of the possibilities of producing parts via the addition of material, defining strategies, and exploring alternative design or optimization solutions (i.e., nonviable using subtractive technologies) of critical parts (e.g., gears and shafts). However, a safe and effective design requires specific resistance data that, due to the intrinsic modernity of additive technologies, are not always present in the literature. This paper presents the results of an experimental campaign performed on gear-samples made by 17-4 PH and produced via Laser Powder Bed Fusion (PBF-LB/M). The tests were executed using the Single Tooth Bending Fatigue (STBF) approach on a mechanical pulsator. The fatigue limit was determined using two different statistical approaches according to Dixon and Little. The obtained data were compared to those reported in the ISO standard for steels of similar performance. Additional analyses, i.e., Scanning Electron Microscopy SEM, were carried out to provide a further insight of the behavior 17-4PH AM material and in order to investigate the presence of possible defects in the tested gears, responsible for the final failure.

Fatigue and Strength Studies of Titanium 6Al–4V Fabricated by Direct Metal Laser Sintering

2015 ◽  
Vol 138 (2) ◽  
Author(s):  
Onome Scott-Emuakpor ◽  
Casey Holycross ◽  
Tommy George ◽  
Kevin Knapp ◽  
Joseph Beck
Keyword(s):  
Fatigue Behavior ◽  
Laser Sintering ◽  
Direct Metal Laser Sintering ◽  
Turbine Engine ◽  
Powder Bed ◽  
Bending Fatigue ◽  
Microstructure Characteristics ◽  
Sixth Generation ◽  
Cold Rolled ◽  
Process Controls

Vibratory bending fatigue behavior of titanium 6Al–4V plate specimens manufactured via direct metal laser sintering (DMLS), powder bed fusion additive manufacturing (AM), is assessed. Motivation for the work is based on unprecedented performance demands for sixth-generation gas turbine engine technology that requires complex, lightweight components. Due to cost, schedule, and feasibility limitations associated with conventional manufacturing, AM aims to address ubiquitous component concepts. Though AM has promise in the engine community, process controls necessary for consistent material properties remain an enigma. The following manuscript compares variability of DMLS fatigue and strength to cold-rolled data. Results show discrepancies between DMLS and cold-rolled for fatigue and microstructure characteristics.

Gear Tooth Bending Fatigue Life Prediction Using Integrated Computational Material Engineering

2017 ◽  
Author(s):  
Michael E. Oja ◽  
Carlos H. Wink ◽  
Nikhil Deo ◽  
Robert L. McDaniels ◽  
Robert G. Tryon ◽  
...  
Keyword(s):  
Gear Tooth ◽  
Fatigue Behavior ◽  
Computational Method ◽  
Vehicle Group ◽  
Cyclic Life ◽  
Bending Fatigue ◽  
Damage Models ◽  
Microstructural Damage ◽  
Single Tooth ◽  
Physical Testing

The paper presents a computational method to predict the cyclic life of gears subjected to single tooth bending fatigue, using VEXTEC’s VPS-MICRO® software. The project was a collaborative effort between Eaton - Vehicle Group and VEXTEC Corporation to replicate physical testing virtually, more specifically to virtually determine bending fatigue curves of gears made from different steels. VPS-MICRO is based on VEXTEC’s patented Virtual Life Management® (VLM®) technology which includes computational microstructural damage models to simulate the fatigue performance and calculate the lifetime of various product configurations. The framework probabilistically estimates the fatigue behavior of a range of Eaton gears and other products.

Estimating the Endurance Limit of 9310, 4340M, and 4360 Steel Gears

2000 ◽  
Author(s):  
Chien Wern ◽  
Hormoz Zareh ◽  
Matt Carter ◽  
Kelly Jones ◽  
Mike Renzelmann
Keyword(s):  
Endurance Limit ◽  
Fatigue Behavior ◽  
Test Fixture ◽  
Bending Fatigue ◽  
Yield Load ◽  
Face Width ◽  
Single Tooth ◽  
Bending Fatigue Test ◽  
Number Of Cycles ◽  
Cycles To Failure

Abstract Single tooth bending fatigue behavior of three gear alloys, namely carburized 9310, induction hardened 4340M and 4360 alloys were examined. The alloys were fabricated into gears having a module of 2.12 (12 diametral pitch) with 12.7 mm (1/2 inch) face width. As the gear geometry was different from that recommended in SAE Single Tooth Gear Bending Fatigue Test standard (SAE-J1619), a test fixture was designed to accommodate these gears. The fixture has the added feature of conjugate action, not found in the SAE test standard. The gears were slowly bent in the fixture to determine the yield load. Then fatigue loads of 85%, 75%, and 65% of yield load were used to determine the number of cycles to failure. The expected endurance limit for single tooth bending fatigue was determined statistically from the finite portion of the load-cycles to failure curve.

Multi-material model for the simulation of powder bed fusion additive manufacturing

2021 ◽  
Vol 194 ◽  
pp. 110415
Author(s):  
Vera E. Küng ◽  
Robert Scherr ◽  
Matthias Markl ◽  
Carolin Körner
Keyword(s):  
Additive Manufacturing ◽  
Material Model ◽  
Powder Bed Fusion ◽  
Powder Bed

scholarly journals A STRUCTURED APPROACH TO REDUCE DESIGN ITERATIONS IN ADDITIVE MANUFACTURING

2021 ◽  
Vol 1 ◽  
pp. 231-240
Author(s):  
Laura Wirths ◽  
Matthias Bleckmann ◽  
Kristin Paetzold
Keyword(s):  
Additive Manufacturing ◽  
Spare Parts ◽  
Design Guidelines ◽  
Final Part ◽  
Layer By Layer ◽  
Powder Bed ◽  
Batch Sizes ◽  
Manufacturing Technologies ◽  
Structured Approach ◽  
Design Freedom

AbstractAdditive Manufacturing technologies are based on a layer-by-layer build-up. This offers the possibility to design complex geometries or to integrate functionalities in the part. Nevertheless, limitations given by the manufacturing process apply to the geometric design freedom. These limitations are often unknown due to a lack of knowledge of the cause-effect relationships of the process. Currently, this leads to many iterations until the final part fulfils its functionality. Particularly for small batch sizes, producing the part at the first attempt is very important. In this study, a structured approach to reduce the design iterations is presented. Therefore, the cause-effect relationships are systematically established and analysed in detail. Based on this knowledge, design guidelines can be derived. These guidelines consider process limitations and help to reduce the iterations for the final part production. In order to illustrate the approach, the spare parts production via laser powder bed fusion is used as an example.

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